Abrasive article having reversible interchangeable abrasive segments

ABSTRACT

An abrasive article is disclosed and can include a core and a plurality of identical segments extending from the core. The segments can be arranged on the core to form first abrasive article indicia on a first side of the abrasive article and second abrasive article indicia on a second side of the abrasive article opposite the first side. The first abrasive article indicia can be identical to the second abrasive article indicia. Moreover, the first abrasive article indicia can be offset with respect to the second abrasive article indicia.

BACKGROUND

1. Field of the Disclosure

The following is generally directed to abrasive tools and processes for forming same, and more particularly, to abrasive tools utilizing abrasive segments attached to a base and methods of assembling such tools.

2. Description of the Related Art

Tools necessary for furthering infrastructure improvements, such as building additional roads and buildings, are vital to the continued economic expansion of developing regions. Additionally, developed regions have a continuing need to replacing aging infrastructure with new and expanded roads and buildings.

The construction industry utilizes a variety of tools for cutting and grinding of construction materials. Cutting and grinding tools are required for to remove or refinish old sections of roads. Additionally, quarrying and preparing finishing materials, such as stone slabs used for floors and building facades, require tools for drilling, cutting, and polishing. Typically, these tools include abrasive segments bonded to a base element or core, such as a plate or a wheel. As with other industries, improvements to these abrasive tools are always sought.

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure may be better understood, and its numerous features and advantages made apparent to those skilled in the art by referencing the accompanying drawings.

FIG. 1 includes a first plan view of an abrasive article in accordance with an embodiment.

FIG. 2 includes a second plan view of an abrasive article in accordance with an embodiment.

FIG. 3 includes a first plan view of a segment in accordance with an embodiment.

FIG. 4 includes a second plan view of a segment in accordance with an embodiment.

FIG. 5 includes a cross-sectional view of a segment taken along line 5-5 in FIG. 3 in accordance with an embodiment.

FIG. 6 includes a perspective view of another abrasive article in accordance with an embodiment.

FIG. 7 includes a detailed view of an abrasive article taken at circle 8 in FIG. 7 in accordance with an embodiment.

FIG. 8 includes a perspective view of another abrasive article in accordance with an embodiment.

FIG. 9 includes a detailed view of an abrasive article taken at circle 9 in FIG. 8 in accordance with an embodiment.

FIG. 10 includes a perspective view of another abrasive article in accordance with an embodiment.

FIG. 11 includes a detailed view of an abrasive article taken at circle 11 in FIG. 10 in accordance with an embodiment.

FIG. 12 includes a perspective view of another abrasive article in accordance with an embodiment.

FIG. 13 includes a detailed view of an abrasive article taken at circle 13 in FIG. 12 in accordance with an embodiment.

FIG. 14 includes a perspective view of another abrasive article in accordance with an embodiment.

FIG. 15 includes a detailed view of an abrasive article taken at circle 15 in FIG. 14 in accordance with an embodiment.

The use of the same reference symbols in different drawings indicates similar or identical items.

DETAILED DESCRIPTION

According to an embodiment, the abrasive article herein can include a core and a plurality of abrasive segments affixed to the core. The abrasive article can be a cutting tool for cutting construction materials, such as a saw for cutting concrete. Alternatively, the abrasive article can be a grinding tool such as for grinding concrete or fired clay or removing asphalt.

In general, the abrasive article can include a first segment and a second segment. The first segment can include a first segment indicia on a first face and second segment indicia on a second face opposite the first face. The second segment can include second segment indicia on a first face and first segment indicia on a second face opposite the first face. The first segment and the second segment can be arranged with respect to each other on the core to define first abrasive article indicia that includes the first segment indicia of the first segment and the second segment indicia of the second segment and second abrasive article indicia that includes the second segment indicia of the first segment and the first segment indicia of the second segment.

In a particular aspect, the first segment and the second segment can include a single segment type. The single segment type can have first segment indicia on a first face and second segment indicia on a second face opposite the first face. Further, the single segment type can be reversible around a periphery of the core to define first abrasive article indicia and second abrasive article indicia opposite the first abrasive article indicia.

FIG. 1 illustrates an exemplary abrasive article designated 100. As depicted, the abrasive article 100 can include a core 102. A plurality of segments 104 can extend outwardly from a perimeter, or circumference, of the core 102. The segments 104 can be formed separately from the core, as described herein, and affixed to the core via a brazing procedure, a welding procedure, a mechanical coupling, etc. In a particular aspect, each adjacent pair of segments 104 can be separated by a gap, such as a gullet 106.

Each gullet can include a first portion 108 that extends from the outer periphery, or circumference, of the adjacent segments 104 toward a center 110 of the core 102. As illustrated, the center 110 of the core 102 is also the center of the abrasive article 100. The first portion 108 of the gullet 106 can extend to a second portion 112 of the gullet 106 that is formed in the core 102. The second portion 112 can extend from an outer periphery of the core 102 toward the center 110 of the core 102. Further, the second portion 112 can terminate in a generally circular end 114. The circular end 114 can be a bore formed through core 102.

The first portion 108 of the gullet can include an open space between two adjacent segments 104 that is defined by a leading edge 116 of a first segment in the pair of segments and a trailing edge 118 of a second segment in the pair of segments 104. The second portion 112 of the gullet 106 can include a slot cut into the core 102. The first portion 108 of the gullet 106 and the second portion 112 of the gullet 106 can be substantially aligned along the same axis. Further, the end 114 can include a center that lies along the central axis of the first portion 108 and the second portion 112 of the gullet 106.

In a particular aspect, the first portion 108 of the gullet 106 can have a first width and the second portion 112 of each gullet 106 can include a second width. The first width can be greater than the second width. The end 114 of the gullet 106 can have a diameter and the diameter can be greater than the first width.

In a particular aspect, as illustrated in FIG. 1 and FIG. 2, the segments 104 are all identical to each other and can be arranged on the core 102 to form a first abrasive article indicia 120 around the outer periphery of the core 102 on a first side of the abrasive article 100 and a second abrasive article indicia 122 around the outer periphery of the core 102 on a second side of the abrasive article 100 opposite the first side. For example, the segments 104 and the abrasive article indicia 120, 122 can be arranged in a ring around the core 102. The first abrasive article indicia 120 can be substantially identical to the second abrasive article indicia 122. Moreover, the first abrasive article indicia 120 can be offset with respect to the second abrasive article indicia 122.

Specifically, if the first abrasive article indicia 120, shown in FIG. 1, was overlaid on the second abrasive article indicia 120, shown in FIG. 2, the first abrasive article indicia 120 would be angularly distanced, or angularly rotated, with respect to the second abrasive article indicia 120 and the first abrasive article indicia 120 would not be aligned with the second abrasive article indicia 120 so as to block out the second abrasive article indicia 120. In other words, if the abrasive article 100 is rotated about an axis 124 passing through the center 110 of the abrasive article 100, the pattern formed around the outer periphery of the core 102 of the abrasive article 100 rotates, or otherwise shifts, from side-to-side by one segment.

In a particular aspect, the first abrasive article indicia 120 can be offset with respect to the second abrasive article indicia 122 by at least one segment 104 so that a first orientation of the first abrasive article indicia 120 is angularly distanced, i.e., rotated, with respect to a second orientation of the second abrasive article indicia 122 on the core 102. As illustrated in FIG. 1 and FIG. 2, the abrasive article can be generally round and the first abrasive article indicia 120 can be angularly offset from the second abrasive article indicia 122 by at least one segment arc length.

As illustrated in FIG. 1 and FIG. 2, the first abrasive article indicia 120 and the second abrasive article indicia 122 each includes a plurality of first segment indicia 130 and a plurality of second segment indicia 130. The plurality of first segment indicia 130 and the plurality of second segment indicia 132 can be arranged in a pattern to define the first abrasive article indicia 120 and the second abrasive article indicia 122. Specifically, the first segment indicia 130 and the second segment indicia 132 can be arranged in a ring around the core 102. Further, the first segment indicia 130 and the second segment indicia 132 can alternate relative to each other around the core 102. In another aspect, each of the first abrasive article indicia 130 and the second abrasive article indicia 132 can include a company name, a product name, a product identifier, a company logo, a product logo, a design, or a combination thereof.

As shown in FIG. 3 and FIG. 4, each segment 104 can include a first face 140 and a second face 142 that is different from and opposite to the first face 140. In particular, the first face 140 and the second face 142 are spaced a distance from each other and are substantially parallel to each other. The first segment indicia 130 can be formed in the first face 140 of the segment 104 and the second segment indicia 130 can be formed in the second face 142 of the segment 104 opposite the first face. In particular, the second segment indicia 142 can be different from the first segment indicia 140.

FIG. 3 and FIG. 4 indicate that the first segment indicia 130 can include a continuous portion 150 that extends continuously along the segment from a leading edge 152 of the segment 104 to a trailing edge 154 of the segment 104. Moreover, the first segment indicia 130 can include at least one other portion 156 located within an area bounded by the continuous portion 150, the leading edge 152 of the segment 104, the trailing edge 154 of the segment 104, and an outer perimeter of the core 102 (or the inner periphery 158 of the segment 104 which is adjacent to, and extends along, the outer perimeter of the core 102).

The second segment indicia 132 of each segment 104 can include a continuous portion 160 that can extend continuously along the segment 104 from the leading edge 152 of the segment 104 to the trailing edge 154 of the segment 104. The second segment indicia 132 of each segment 104 can also include at least one other portion 162 that is located within an area bounded by the continuous portion 160, the leading edge 152 of the segment 104, the trailing edge 154 of the segment 104, and an outer perimeter of the core 102 or an inner periphery 158 of the segment.

In a particular aspect, the continuous portion 150 of the first segment indicia 130 is the same shape as the continuous portion 160 of the second segment indicia 132. However, the at least one other portion 156 of the first segment indicia 130 can be different that the at least one other portion 162 of the second segment indicia 132.

As depicted in FIG. 3 and FIG. 4, the segment 104 can include a first relief portion 170 formed in the first face 140 of the segment. The first relief portion 170 can be formed by pressing a portion of the material of the segment 104 into the segment 104 away from the first face 140. This can be performed during a molding process. The molding process can include pressing a green segment using a hot pressing operation, a cold pressing operation, or some other pressing operation. In a particular aspect, the first relief portion 170 can at least partially surround the first segment indicia 130.

Further, the first relief portion can include a substantially uniform first depth, D₁, that is measured perpendicularly into the segment 104 from the first face 140 of the segment 104. In one aspect, D₁ can be ≧5% of the segment thickness, T, measured from the first face 140 to the second face 142. For example, D₁ can be ≧10% T, or ≧15% T. In another aspect, D₁ can be ≦30% T, such as ≦25% T, or ≦20% T. Further, D₁ can be within a range between and including any of the % of T values above.

Each segment 104 can also include a second relief portion 172 formed in the second face 132 in the same manner as the first relief portion 170. The second relief portion 172 can at least partially surround the second segment indicia 132. Also, the second relief portion 172 includes a second depth, D₂, that is measured perpendicularly into the segment 104 from the second face 142 of the segment 104. In one aspect, D₂ can be ≧5% T, such as ≧10% T, or ≧15% T. In another aspect, D₂ can be ≦30% T, such as ≦25% T, or ≦20% T. Further, D₂ can be within a range between and including any of the % of T values above. Moreover, D₁=D₂±5% D₂, such as D₂±4% D₂, D₂±3% D₂, D₂±2% D₂, or D₂±1% D₂. In another aspect, D₁=D₂.

In a particular aspect, the relief portions 170, 172 can be established by removing material from the first face 130 and second face 132 of the segment 104. In such an aspect, the material removed from each face 130, 132 of the segment 104 should be substantially the same in order to maintain balance and prevent vibration of the abrasive article 100 during use. If D₁=D₂, the same volume of material can be removed from each face 130, 132, or compressed, by removing or compressing material over the same total area of each face 130, 132. Accordingly, the first face 130 of the segment 104 can include an overall surface area, A_(F1), before the first relief portion 170 is formed. After the first relief portion 170 is formed, the resulting first segment indicia 130 can have a first segment indicia surface area, A_(SI1). Similarly, the second face 132 of the segment can include an overall surface area, A_(F2), before the second relief portion 172 is formed. After the second relief portion 172 is formed, the resulting second segment indicia 132 can have a second segment indicia surface area A_(SI2).

In a particular aspect, A_(SI1) can be ≦45% A_(F)1, such as ≦40% A_(F)1, or ≦35% A_(F1). Further, A_(SI1) can be ≧10% A_(F1), such as ≧15% A_(F1), >20% A_(F1), or ≧25% A_(F1). A_(SI1) can be in a range between and including any of the area values described above.

Similarly, A_(SI2) can be ≦45% A_(F2), such as ≦40% A_(F2), or ≦35% A_(F2). Moreover, A_(SI2) can be ≧10% A_(F2), such as ≧15% A_(F2), >20% A_(F2), or ≧25% A_(F2). A_(SI2) can be in a range between and including any of the area values described above.

Additionally, in a particular aspect, A_(SI1) can=A_(SI2)±5% A_(SI2), such as A_(SI2)±4% A_(SI2), A_(SI2)±3% A_(SI2), A_(SI2)±2% A_(SI2), or A_(SI2)±1% A_(SI2). Further, AS_(I1) can=A_(SI2).

Referring now to FIG. 6 and FIG. 7, another abrasive article is illustrated and is designated 600. The abrasive article 600 can include a core 602. A plurality of segments 604 can extend outwardly from a perimeter, or circumference, of the core 602. Each adjacent pair of segments 604 can be separated by a gap, such as a gullet 606.

In a particular aspect, as illustrated in FIG. 6 and FIG. 7, the segments 604 are all identical to each other and can be arranged on the core 602 to form a first abrasive article indicia 620 around the outer periphery of the core 602 on a first side of the abrasive article 600 and a second abrasive article indicia (not shown) around the outer periphery of the core 602 on a second side of the abrasive article 600 opposite the first side. The first abrasive article indicia 620 can be substantially identical to the second abrasive article indicia. Moreover, the first abrasive article indicia 620 can be offset with respect to the second abrasive article indicia.

As illustrated in FIG. 6 and FIG. 7, the first abrasive article indicia 620 can include a plurality of first segment indicia 630 and a plurality of second segment indicia 632. The plurality of first segment indicia 630 and the plurality of second segment indicia 632 can be arranged in a pattern, e.g., a ring, to define the first abrasive article indicia 620 and the second abrasive article indicia. Each of the first abrasive article indicia 630 and the second abrasive article indicia 632 can include a company name, a product name, a product identifier, a company logo, a product logo, a design, or a combination thereof.

FIG. 8 and FIG. 9 depict another abrasive article 800. The abrasive article 800 can include a core 802. A plurality of segments 804 can extend outwardly from a perimeter, or circumference, of the core 802. Each adjacent pair of segments 804 can be separated by a gap, such as a gullet 806.

As illustrated in FIG. 8 and FIG. 9, the segments 804 are all identical to each other and can be arranged on the core 802 to form a first abrasive article indicia 820 around the outer periphery of the core 802 on a first side of the abrasive article 800 and a second abrasive article indicia (not shown) around the outer periphery of the core 802 on a second side of the abrasive article 800 opposite the first side. The first abrasive article indicia 820 can be substantially identical to the second abrasive article indicia. Moreover, the first abrasive article indicia 820 can be offset with respect to the second abrasive article indicia.

The first abrasive article indicia 820 can include a plurality of first segment indicia 830 and a plurality of second segment indicia 832. The plurality of first segment indicia 830 and the plurality of second segment indicia 832 can be arranged in a pattern, e.g., a ring, to define the first abrasive article indicia 820 and the second abrasive article indicia. Each of the first abrasive article indicia 830 and the second abrasive article indicia 832 can include a company name, a product name, a product identifier, a company logo, a product logo, a design, or a combination thereof.

Referring to FIG. 10 and FIG. 11, yet another abrasive article 1000 is depicted. As illustrated, the abrasive article 1000 can include a core 1002. A plurality of segments 1004 can extend outwardly from a perimeter, or circumference, of the core 1002. Each adjacent pair of segments 1004 can be separated by a gap, such as a gullet 1006.

As indicated in FIG. 10 and FIG. 11, the segments 1004 are all identical to each other and can be arranged on the core 1002 to form a first abrasive article indicia 1020 around the outer periphery of the core 1002 on a first side of the abrasive article 1000 and a second abrasive article indicia (not shown) around the outer periphery of the core 1002 on a second side of the abrasive article 1000 opposite the first side. The first abrasive article indicia 1020 can be substantially identical to the second abrasive article indicia. Moreover, the first abrasive article indicia 1020 can be offset with respect to the second abrasive article indicia.

In a particular aspect, the first abrasive article indicia 1020 can include a plurality of first segment indicia 1030 and a plurality of second segment indicia 1032. The plurality of first segment indicia 1030 and the plurality of second segment indicia 1032 can be arranged in a pattern, e.g., a ring, to define the first abrasive article indicia 1020 and the second abrasive article indicia. Each of the first abrasive article indicia 1030 and the second abrasive article indicia 1032 can include a company name, a product name, a product identifier, a company logo, a product logo, a design, or a combination thereof.

Referring now to FIG. 12 and FIG. 13, yet another abrasive article 1200 is illustrated. The abrasive article 1200 can include a core 1202. A plurality of segments 1204 can extend outwardly from a perimeter, or circumference, of the core 1202. Each adjacent pair of segments 1204 can be separated by a gap, such as a gullet 1206.

As illustrated in FIG. 12 and FIG. 13, the segments 1204 are all identical to each other and can be arranged on the core 1202 to form a first abrasive article indicia 1220 around the outer periphery of the core 1202 on a first side of the abrasive article 1200 and a second abrasive article indicia (not shown) around the outer periphery of the core 1202 on a second side of the abrasive article 1200 opposite the first side. The first abrasive article indicia 1220 can be substantially identical to the second abrasive article indicia. In a particular aspect, the first abrasive article indicia 1220 can be offset with respect to the second abrasive article indicia.

Additionally, the first abrasive article indicia 1220 can include a plurality of first segment indicia 1230 and a plurality of second segment indicia 1232. The plurality of first segment indicia 1230 and the plurality of second segment indicia 1232 can be arranged in a pattern, e.g., a ring, to define the first abrasive article indicia 1220 and the second abrasive article indicia. Each of the first abrasive article indicia 1230 and the second abrasive article indicia 1232 can include a company name, a product name, a product identifier, a company logo, a product logo, a design, or a combination thereof.

FIG. 14 and FIG. 15 illustrate still another abrasive article 1400. The abrasive article 1400 can include a core 1402 and a plurality of segments 1404 can extend outwardly from a perimeter, or circumference, of the core 1402. Each adjacent pair of segments 1404 can be separated by a gap, such as a gullet 1406.

In a particular aspect, the segments 1404 are all identical to each other and can be arranged on the core 1402 to form a first abrasive article indicia 1420 around the outer periphery of the core 1402 on a first side of the abrasive article 1400 and a second abrasive article indicia (not shown) around the outer periphery of the core 1402 on a second side of the abrasive article 1400 opposite the first side. The first abrasive article indicia 1420 can be substantially identical to the second abrasive article indicia. Moreover, the first abrasive article indicia 1420 can be offset with respect to the second abrasive article indicia.

As illustrated in FIG. 14 and FIG. 15, the first abrasive article indicia 1420 can include a plurality of first segment indicia 1430 and a plurality of second segment indicia 1432. The plurality of first segment indicia 1430 and the plurality of second segment indicia 1432 can be arranged in a pattern, e.g., a ring, to define the first abrasive article indicia 1420 and the second abrasive article indicia. Each of the first abrasive article indicia 1430 and the second abrasive article indicia 1432 can include a company name, a product name, a product identifier, a company logo, a product logo, a design, or a combination thereof.

In a particular aspect, the core of each abrasive article described herein can be in the form of a ring, a ring section, a plate, or a disc depending upon the intended application of the abrasive article. The core can be made of a metal or metal alloy. For instance, the base can be made of steel, and particularly, a heat treatable steel alloys, such as 25CrMo4, 75Cr1, C60, or similar steel alloys for a core having a thin cross section or simple construction steel like St 60 or similar for a thick core. The core can have a tensile strength of at least about 600 N/mm². The core can be formed by a variety of metallurgical techniques known in the art.

In an exemplary embodiment, an abrasive segment includes abrasive particles embedded in a bond matrix. The bond matrix can include a metal matrix having a network of interconnected pores. The abrasive particles can include an abrasive material having a Mohs hardness of at least about 7. In particular instances, the abrasive particles can include a superabrasive material, such as diamond or cubic boron nitride. The abrasive particles can have a particle size of not less than about 400 US mesh, such as not less than about 100 US mesh, such as between about 25 and 80 US mesh. Depending on the application, the size can be between about 30 and 60 US mesh.

The abrasive particles can be present in an amount between about 2 vol % to about 50 vol %. Additionally, the amount of abrasive particles may depend on the application. For example, an abrasive segment for a grinding or polishing tool can include between about 3.75 and about 50 vol % abrasive particles of the total volume of the abrasive segment. Alternatively, an abrasive segment for a cutting-off tool can include between about 2 vol % and about 6.25 vol % abrasive particles of the total volume of the abrasive segment. Further, an abrasive segment for core drilling can include between about 6.25 vol % and about 20 vol % abrasive particles of the total volume of the abrasive segment.

The metal matrix can include a metal element or metal alloy including a plurality of metal elements. For certain abrasive segments, the metal matrix can include metal elements such as iron, tungsten, cobalt, nickel, chromium, titanium, silver, and a combination thereof. In particular instances, the metal matrix can include a rare earth element such as cerium, lanthanum, neodymium, and a combination thereof.

In one particular example, the metal matrix can include a wear resistant component. For example, in one embodiment, the metal matrix can include tungsten carbide, and more particularly, may consist essentially of tungsten carbide.

In certain designs, the metal matrix can include particles of individual components or pre-alloyed particles. The particles can be between about 1.0 microns and about 250 microns.

As noted above, the abrasive segment can be formed such that an infiltrant is present within the interconnected network of pores within the body of the abrasive segment. The infiltrant can partially fill, substantially fill, or even completely fill the volume of the pores extending through the volume of the abrasive segment. In accordance with one particular design, the infiltrant can be a metal or metal alloy material. For example, some suitable metal elements can include copper, tin, zinc, and a combination thereof.

In particular instances, the infiltrant can be a bronzing material made of a metal alloy, and particular a copper-tin metal alloy, such that it is particularly suited for welding according to embodiments herein. For example, the bronzing material can consist essentially of copper and tin. Certain bronzing materials can incorporate particular contents of tin, such as not greater than about 20%, not greater than about 15%, not greater than about 12%, or even not greater than about 10% of the total amount of materials within the composition. In accordance with an embodiment, the bronzing material can include an amount of tin within a range between about 5% and about 20%, such as between about 8% and about 15%, or even between about 8% and about 12%.

Moreover, certain bronzing materials can be used as infiltrant material, and can have an amount of copper of at least about 80%, at least about 85%, or even at least about 88% of the total amount of materials within the composition. Some bronzing materials can utilize an amount of copper within a range between about 80% and about 95%, such as between about 85% and about 95%, or even between about 88% and about 93%.

Additionally, the bronzing material may contain a particularly low content of other elements, such as zinc to facilitate proper formation of the abrasive article according to the forming methods of the embodiments herein. For example, the bronzing material may utilize not greater than about 10%, such as not greater than about 5%, or even not greater than about 2% zinc. In fact, certain bronzing materials can be essentially free of zinc.

The abrasive segment may be manufactured, such that abrasive particles can be combined with a metal matrix to form a mixture. The metal matrix can include a blend of particles of the components of the metal matrix or can be pre-alloyed particles of the metal matrix. In an embodiment, the metal matrix can conform to the formula (WC)_(w)W_(x)Fe_(y)Cr_(z)X_((1-v-w-x-y-z)), wherein 0≦w≦0.8, 0≦x≦0.7, 0≦y≦0.8, 0≦z≦0.05, w+x+y+z≦1, and X can include other metals such as cobalt and nickel. In another embodiment, the metal matrix can conform to the formula (WC)_(w)W_(x),Fe_(y)Cr_(z)Ag_(v)X_((1-v-w-x-y-z)), wherein 0≦w≦0.5, 0≦x≦0.4, 0≦y≦1.0, 0≦z≦0.05, 0≦v≦0.1, v+w+x+y+z≦1, and X can include other metals such as cobalt and nickel.

The mixture of metal matrix and abrasive particles can be formed into an abrasive preform by a pressing operation, particularly a cold pressing operation, to form a porous abrasive segment. The cold pressing can be carried out at a pressure of between about 50 kN/cm² (500 MPa) to about 250 kN/cm² (2500 MPa). The resulting porous abrasive segment can have a network of interconnected pores. In an example, the porous abrasive segment can have a porosity between about 25 and 50 vol %.

The resulting porous abrasive segment can then be subject to an infiltration process, wherein the infiltrant material is disposed within the body of the abrasive segment, and particularly, disposed within the interconnected network of pores within the body of the abrasive segment. The infiltrant may be drawn into the pores of the cold pressed abrasive segment via capillary action. After the infiltration process, the resulting densified abrasive segment can be not less than about 96% dense. The amount of infiltrant that infiltrates the abrasive segment can be between about 20 wt % and 45 wt % of the densified abrasive segment.

The abrasive segment can include a backing region, disposed between the abrasive segment and the base, i.e., the core, which facilitates the joining of the abrasive segment and the base. According to one embodiment, the backing region can be a distinct region from the abrasive segment and the base. Still, the backing region can be initially formed as part of the abrasive segment, and particularly may be a distinct region of the abrasive segment that has particular characteristics facilitating the joining of the abrasive segment and the base. For example, according to one embodiment, the backing region can have a lesser percentage (vol %) of abrasive particles as compared to the amount of abrasive particles within the abrasive segment. In fact, in certain instances, the backing region can be essentially free of abrasive particles. This may be particularly suitable for forming methods utilizing a beam of energy (e.g., a laser) used to weld the abrasive segment to the base.

At least a portion of the backing region can include a bonding composition. The bonding composition can include a metal or metal alloy. Some suitable metal materials can include transition metal elements, including for example, titanium, silver, manganese, phosphorus, aluminum, magnesium, chromium, iron, lead, copper, tin, and a combination thereof.

In particular instances, the bonding composition can be similar to the infiltrant, such that the bonding composition and the infiltrant are different from each other by not greater than a single elemental species. In even more particular instances, the bonding composition can be the same as the infiltrant. According to embodiments herein, the bonding composition can be related to the infiltrant composition in having a certain degree of commonality of elemental species. Quantitatively, an elemental weight percent difference between the bonding composition and the infiltrant composition does not exceed 20 weight percent. Elemental weight percent difference is defined as the absolute value of the difference in weight content of each element contained in the bonding composition relative to the infiltrant composition. Other embodiments have closer compositional relationships between the bonding composition and the composition of the infiltrant. The elemental weight percent difference between the bonding composition and the infiltrant composition may, for example, not exceed 15 weight percent, 10 weight percent, 5 weight percent, or may not exceed 2 weight percent. An elemental weight percent difference of about zero represents the same composition making up the backing region and the infiltrant. The foregoing elemental values may be measured by any suitable analytical means, including microprobe elemental analysis, and ignores alloying that might take place along areas in which the infiltrant contacts the metal matrix.

The backing region can include at least about 90 wt % infiltrant, such as at least about 95 wt % infiltrant, such as at least about 98 wt % infiltrant. The infiltrant can be continuous throughout the backing region and the densified abrasive segment. In certain instances, the backing region can be formed primarily of the infiltrant material, and in more particular instances, can consist essentially of the infiltrant material. Still, in other embodiments, the backing region can be an infiltrated region, like the abrasive segment. Accordingly, the backing region can include a network of interconnected pores formed between a matrix metal, and wherein the infiltrant material substantially fills the interconnected pores. The backing region can contain similar amounts of matrix metal and infiltrant. Notably, the backing region may be essentially free of abrasive particles. In such embodiments wherein the backing region includes interconnected pores substantially filled with the infiltrant, the infiltrant material can act as a bronzing material in forming a joint (e.g., a welded joint) between the base and the abrasive segment.

In one embodiment, the backing region can be formed of the bronzing material described herein. In fact, certain backing regions can consist essentially of a copper-tin bronzing material having about 88% copper and 12% tin or 90% copper and 10% tin.

In general, an abrasive article as described herein can be made by forming a plurality of segments. Each of the plurality of segments can include first segment indicia on a first face and second segment indicia on a second face that is opposite the first face. While each of the plurality of segments is identically constructed, the first segment indicia on a single segment are different from the second segment indicia on the segment. The segments can be configured to establish first abrasive article indicia on a first side of the abrasive article and second abrasive article indicia on a second side of the abrasive article opposite the first side. The first abrasive article indicia and the second abrasive article indicia can include at least one first segment indicia and at least one second segment indicia. The shape of the abrasive article indicia, i.e., the generally sinusoidal or wave-shape, around the periphery of the abrasive article can serve to pump cutting fluid into and out of a cutting area as the abrasive article rotates. This pumping action can aid in cooling the cutting area and cleaning the cutting area of swarf or debris. In addition, the abrasive article indicia can serve as an identifier of the abrasive article, the manufacturer of the abrasive article, etc.

The method of making the abrasive article can include affixing a first of the plurality of segments to a core such that the first segment indicia is facing a first direction and the second segment indicia is facing a second direction opposite the first direction and affixing a second of the plurality of segments to a core such that the second segment indicia is facing the first direction and the first segment indicia is facing the second direction. In this aspect, the first segment is rotated 180° with respect to the second segment.

Affixing the segments to the core can include welding the abrasive segments to the core. In particular, the welding process can include impinging a beam of energy at the base of each segment. More particularly in the instance of a segment having a backing region, welding can include impinging a beam of energy at the backing region between the abrasive segment and the core. In particular instances, the beam of energy can be a laser, such that each abrasive segment is attached to the core via a laser welded bond joint. The laser may be a Roffin laser source commonly available from Dr. Fritsch, GmbH.

In one aspect, each segment can be formed by pressing a green segment in a mold and curing the green segment. The pressing can include hot pressing or cold pressing. In another aspect, forming each segment can include sintering a green segment, e.g., using an electro-discharge sintering process. In yet another aspect, forming each segment can include the infiltration method described herein.

The abrasive article described herein can also be made by forming a plurality of segments in which each segment includes first segment indicia on a first face and second segment indicia on a second face. While the segments are identical, the first segment indicia are different from the second segment indicia. This method can also include arranging the segments to establish a first abrasive article indicia on a first side of the abrasive article and a second abrasive article indicia on a second side of the abrasive article. The first abrasive article indicia and the second abrasive article indicia comprise at least one first segment indicia and at least one second segment indicia. Further, the first abrasive article indicia and the second abrasive article indicia are identical. However, the first abrasive article indicia are angularly offset with respect to the second abrasive article indicia.

According to an embodiment, the abrasive article includes a carrier element, e.g., a core, and an abrasive component. The abrasive article can be a cutting tool for cutting construction materials, such as a saw for cutting concrete. Alternatively, the abrasive article can be a grinding tool such as for grinding concrete or fired clay or removing asphalt. In particular, the following embodiments have formulated a method for the welding of infiltrated abrasive segments onto a base for use in an abrasive article.

In the foregoing, reference to specific embodiments and the connections of certain components is illustrative. It will be appreciated that reference to components as being coupled or connected is intended to disclose either direct connection between said components or indirect connection through one or more intervening components as will be appreciated to carry out the methods as discussed herein. As such, the above-disclosed subject matter is to be considered illustrative, and not restrictive, and the appended claims are intended to cover all such modifications, enhancements, and other embodiments, which fall within the true scope of the present invention. Thus, to the maximum extent allowed by law, the scope of the present invention is to be determined by the broadest permissible interpretation of the following claims and their equivalents, and shall not be restricted or limited by the foregoing detailed description.

The Abstract of the Disclosure is provided to comply with Patent Law and is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. In addition, in the foregoing Detailed Description of the Drawings, various features may be grouped together or described in a single embodiment for the purpose of streamlining the disclosure. This disclosure is not to be interpreted as reflecting an intention that the claimed embodiments require more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive subject matter may be directed to less than all features of any of the disclosed embodiments. Thus, the following claims are incorporated into the Detailed Description of the Drawings, with each claim standing on its own as defining separately claimed subject matter. 

1. An abrasive article, comprising: a core; and a plurality of identical segments extending from the core, wherein the segments are arranged on the core to form first abrasive article indicia on a first side of the abrasive article and second abrasive article indicia on a second side of the abrasive article opposite the first side, wherein the first abrasive article indicia are substantially identical to the second abrasive article indicia and wherein the first abrasive article indicia are offset with respect to the second abrasive article indicia.
 2. The abrasive article of claim 1, wherein the first abrasive article indicia are offset with respect to the second abrasive article indicia by at least one segment.
 3. The abrasive article of claim 2, wherein the first abrasive article indicia include a first orientation relative to the core and the second abrasive article indicia include a second orientation relative to the core and wherein the first orientation is angularly distanced from the second orientation.
 4. The abrasive article of claim 1, wherein each of the first abrasive article indicia and the second abrasive article indicia includes a plurality of first segment indicia and a plurality of second segment indicia, wherein the plurality of first segment indicia and the plurality of second segment indicia are arranged in a pattern to define the first abrasive article indicia and the second abrasive article indicia.
 5. The abrasive article of claim 4, wherein each of the first abrasive article indicia and the second abrasive article indicia includes a company name, a product name, a product identifier, a company logo, a product logo, a design, or a combination thereof.
 6. The abrasive article of claim 5, wherein adjacent segments are separated by a gap.
 7. The abrasive article of claim 6, wherein adjacent segments are separated by a gullet. 8-31. (canceled)
 32. An abrasive article, comprising: a core; and a first segment extending from the core, the first segment having first segment indicia on a first face and second segment indicia on a second face opposite the first face; a second segment extending from the core, the second segment having second segment indicia on a first face and first segment indicia on a second face opposite the first face; and wherein the first segment and the second segment are arranged with respect to each other to define first abrasive article indicia that includes the first segment indicia of the first segment and the second segment indicia of the second segment and second abrasive article indicia that includes the second segment indicia of the first segment and the first segment indicia of the second segment.
 33. (canceled)
 34. (canceled)
 35. The abrasive article of claim 32, wherein each of the first abrasive article indicia and the second abrasive article indicia includes a plurality of first segment indicia and a plurality of second segment indicia, wherein the plurality of first segment indicia and the plurality of second segment indicia are arranged in a pattern to define the first abrasive article indicia and the second abrasive article indicia.
 36. (canceled)
 37. The abrasive article of claim 35, wherein the plurality of first segment indicia and the plurality of second segment indicia alternate relative to each other around the core. 38-44. (canceled)
 45. The abrasive article of claim 37, wherein each segment includes a first face and a second face opposite the first face and the first segment indicia are formed in the first face and the second segment indicia are formed in the second face.
 46. The abrasive article of claim 45, wherein each segment includes a first relief portion in the first face that at least partially surrounds the first segment indicia, wherein the first relief portion includes a first depth, D₁, from the first face of the segment and wherein D₁ is ≧5%.
 47. The abrasive article of claim 46, wherein D₁ is ≦30% T.
 48. The abrasive article of claim 47, wherein each segment includes a second relief portion in the second face that at least partially surrounds the second segment indicia, wherein the second relief portion includes a second depth, D₂, from the second face of the segment and wherein D₂ is ≧5% T.
 49. The abrasive article of claim 48, wherein D₂ is ≦30% T.
 50. The abrasive article of claim 49, wherein D1=D2±5% D2.
 51. (canceled)
 52. The abrasive article of claim 46, wherein the first face includes an overall surface area, A_(F1), and the first segment indicia include a surface area, A_(SI1), and A_(SI1) is ≦45% A_(F1).
 53. The abrasive article of claim 52, wherein A_(SI1) is ≧10% A_(F1).
 54. The abrasive article of claim 53, wherein the second face includes an overall surface area, A_(F2), and the second segment indicia include a surface area, A_(SI2), and A_(SI2) is ≦45% A_(F2).
 55. (canceled) 56-77. (canceled)
 78. A method of making an abrasive article, the method comprising: forming a plurality of segments, wherein each segment includes first segment indicia on a first face and second segment indicia on a second face opposite the first face, wherein the first segment indicia are different from the second segment indicia, wherein the segments are configured to establish first abrasive article indicia on a first side of the abrasive article and second abrasive article indicia on a second side of the abrasive article opposite the first side, wherein the first abrasive article indicia and the second abrasive article indicia comprise at least one first segment indicia and at least one second segment indicia. 79-89. (canceled) 